Category Archives: Innovation

Die optimale Lösung für hochpräzise Positionieraufgaben

Zykloidgetriebe von Nabtesco leisten nicht nur in Robotern hervorragende Arbeit, sie ermöglichen auch die exakte Positionierung von Rohlingen und Werkzeugmagazinen in Werkzeugmaschinen.

Die Zykloidgetriebe zeichnen sich durch eine sehr hohe Positioniergenauigkeit und Steifigkeit sowie eine besonders kompakte Bauform aus. Nabtesco bietet nicht nur diverse, in den Baugrößen abgestimmte Einbausätze mit und ohne Schrägkugellager an. Für Anwendungen mit geringem Bauraum finden Anwender außerdem zahlreiche Exzentergetriebe mit Hohlwelle im Produktprogramm: Hier lassen sich Datenkabel, Versorgungsleitungen oder Antriebswellen einfach und platzsparend durch die Mitte des Getriebes führen.

Dank der hohen Drehmomentleistungen, dem minimalen Spiel von weniger als einer Winkelminute und sehr hoher Steifigkeit sind die Zykloidgetriebe in der Lage, selbst hohe Traglasten ohne Nachschwingen schnell und präzise zu positionieren. Diese besonderen Eigenschaften verdanken die Getriebe ihrem Funktionsprinzip mit zweistufiger Untersetzung: Die doppelten Kurvenscheiben reduzieren die Drehzahl, so dass kaum Vibrationen entstehen. Da die Kraft sich durch die Rollen-Exzenter-Konstruktion zudem gleichmäßig verteilt, überstehen die Getriebe sogar eine Schockbelastung vom Fünffachen des Nenndrehmoments.

Getriebeserien für unterschiedliche Anwendungen erhältlich
Nabtesco fertigt verschiedene Baureihen seiner Zykloidgetriebe, die unterschiedliche Besonderheiten aufweisen. Die neuen RF-P-Einbausätze eignen sich z. B. ideal für den Einsatz in automatischen Werkzeugwechslern (ATC), da sie für Hochgeschwindigkeitsanwendungen auf engstem Bauraum konzipiert wurden. Speziell auf die exakte Positionierung von Magazinen in Werkzeugmaschinen sind dagegen die Getriebe der RA-EA/EC-Serie ausgelegt. Diese Ausführung hat eine sehr hohe Überlastfähigkeit, hohe Untersetzungen und eine angepasste Gehäuseform, die eine schnelle Integration in Scheiben- oder Kettenmagazine ermöglicht. Die ganzzahlige Untersetzung sorgt für eine punktgenaue Positionierung des Werkzeugwechslers.

Die RS-Serie findet häufig im Antrieb horizontaler Drehtische Verwendung. Diese hochpräzisen Hohlwellengetriebe mit integriertem Winkelgetriebe sorgen für die exakte Aufbringung von Schweißpunkten im Zehntelmillimeter-Bereich. Das RS-Getriebe ist für sehr schwere Lasten ausgelegt und kann dank seiner gusseisernen Basis einfach auf dem Boden montiert werden, so dass ein stabiler Stand gegeben ist. Die RS-Serie unterstützt Nenndrehmomente zwischen 2.548 und 8.820 Nm sowie Beschleunigungs- bzw. Bremsmomente bis zu 17.640 Nm. Das integrierte Hauptlager erlaubt den Einsatz in Anwendungen mit Axiallasten von bis zu 9 t.

Die RH-N-Baureihe ist aufgrund ihrer hohen Leistungsdichte besonders für hohe Traglasten geeignet. Das Getriebe lässt sich flexibel an alle marktführenden Servoantriebe anpassen und ist wegen seines innovativen Tribologiekonzepts extrem wartungsarm. Da Antriebsritzel und ein Motorflansch für die gängigsten Motortypen in den Getriebekopf integriert sind, kann der Konstrukteur das Getriebe einfach per Plug-and-Play in die Anwendung einsetzen.

www.nabtesco.com

Sandvik Coromant and PARC Partner to Advance Digital Manufacturing

Sandvik Coromant is strengthening its capabilities in Digital Manufacturing by signing a strategic research agreement with PARC, a Xerox company, world-renowned innovation center. PARC will provide Sandvik Coromant with a footprint in Silicon Valley and expert resources for research & development in the field of Digital Manufacturing.

PARC will allocate resources to conduct research & develop technologies within Digital Manufacturing for Sandvik Coromant under the terms of the agreement. Sandvik Coromant will also acquire all Intellectual Property (IP) and technology related to PARC’s software for high-level process planning and automated manufacturing cost estimation for subtractive manufacturing.

“This partnership is a natural step and in line with Sandvik Coromant’s long-term strategy to develop attractive solutions in the field of digital manufacturing and Industry 4.0,” said Magnus Ekbäck, Vice President and Head of Business Development and Digital Machining for Sandvik Coromant. “With this cooperation we will significantly strengthen our capabilities within digital machining.”

“Manufacturing is entering a dynamic new phase as the cyber and physical worlds converge, and the complex and diverse industry needs significant innovation to truly progress,” said PARC CEO Tolga Kurtoglu. “The missing piece for complete design automation and manufacturing of complex products has been the integrated coupling of design and manufacturing, which we have been developing at PARC for many years. We’re pleased to partner with Sandvik Coromant to see these innovations come to life on the global stage.”

PARC has been developing technologies for government agencies and commercial clients in the field of digital manufacturing for almost a decade. Its digital manufacturing suite of technologies helps designers and manufacturers understand real-world manufacturing process constraints during digital product design and identifies potential limitations of a supply chain early in the design phase, ultimately minimizing time-to-market and improving overall product quality.

The strategic research agreement will be governed by a Joint Steering Committee with representatives from both PARC and Sandvik Coromant.

www.sandvik.coromant.com

www.parc.com

Refill it! Motorex Mini Sprays

Spray like the big boys: Take compact, refillable Mini Sprays with you and use them anywhere – The perfect addition to the Motorex spray range.

Create your own practical Mini Sprays in just a few steps: 1. Take an empty can from the Motorex Mini Spray package. 2.Choose the product you want and apply the appropriate label to the Mini Spray. 3. Remove the lids and spray nozzles. 4. Shake the large original spray can. 5. Place the empty Mini Spray on a firm, level surface and fill it for 30 seconds. 6.Attach the spray nozzle and lid and you’re done!
Create your own practical Mini Sprays in just a few steps: 1. Take an empty can from the Motorex Mini Spray package. 2.Choose the product you want and apply the appropriate label to the Mini Spray. 3. Remove the lids and spray nozzles. 4. Shake the large original spray can. 5. Place the empty Mini Spray on a firm, level surface and fill it for 30 seconds. 6. Attach the spray nozzle and lid and you’re done!

Motorex developed its versatile Hi-Tech sprays for daily professional use. If you just need a little, but it has to be handy at all times, the new Mini Sprays are just the thing.

Motorex refill system
The idea for Mini Sprays, which can be refilled as often as users want, stems from the fact that large (500 ml) spray cans are not always convenient to use. Each Mini Spray kit consists of three empty 50-ml spray cans. Each can has a base label, and the package contains a sheet of self-adhesive labels for the most commonly used sprays from the Hi-Tech range.

Now any user can put together a personalized set of the sprays they use most often. Just choose the right label from the sheet and apply it to the space intended for it on the Mini Spray. The refillable MINIS are filled straight from the large standard spray can, which functions as a dispenser. Just place the empty Mini Spray on a firm, level surface, remove the spray nozzles from both cans, shake the dispenser and fill the small spray.

Always at hand
Many users told Motorex how inconvenient it can be to carry a large spray can while assembling equipment or working in cramped spaces. The company responded by introducing a REFILL SYSTEM for its nine most popular Hi-Tech sprays.

100 % Swiss made by Motorex
All Motorex sprays are developed in Langenthal, tested in professional real-world practice and then produced at our own production facilities. This approach enables Motorex to offer the right spray for every application.

Try refillable Mini Sprays now!Motorex_Refill_System_01 copie

Motorex AG Langenthal
Customer Service
Case postale
CH-4901 Langenthal
Tél. +41 62 919 74 74
Fax +41 62 919 76 96
www.motorex.com

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Delcam in project to revolutionise manufacture of titanium alloy aircraft parts

Delcam has partnered with Cranfield University, Airbus Group and the University of Bath in a major project looking at the use of Additive Layer Manufacturing (ALM, more commonly known as 3-D printing) to revolutionise the production of titanium alloy aircraft components.

Members of the RAWFEED team meet at Delcam to discuss progress in the project.
Members of the RAWFEED team meet at Delcam to discuss progress in the project.

The £995,000 project, which began at the Cranfield University Welding Engineering and Laser Processing Centre in January 2014, is looking at the industrial potential of RAWFEED, Rolling Assisted Wire Feed Direct Deposition for Production of High Value Aerospace Components.  The ALM process would reduce waste in the manufacture of titanium components from the current 80-90% to 30-35%, and increase production speed 50-fold compared to components manufactured using conventional methods.

Step by step
The RAWFEED process uses a welding torch to deposit a continuous bead of material on a titanium baseplate, creating the first layer of the component.  The layer is allowed to cool and is then rolled to enhance the material’s properties.  This process is repeated until the required 3D shape is completed. Managed by Airbus and supported by £630,000 support from the UK Technology Strategy Board, the research is looking to validate a cost model and define the machine architecture and specification to exploit the industrial potential of this emerging technology.

Huge potential
Delcam is providing the high quality control software for the project over a wide range of machine tool and robotic platforms.  The University of Bath’s Laboratory for Integrated Metrology Applications (LIMA) will develop a measuring system that will help control and quality assure the process. Curtis Carson, Head of Systems Integration – Manufacturing Engineering at Airbus Group commented: “Airbus currently procures £250m of these components every year, so the savings in terms of waste and production efficiency are enormous. We are proud to be associated with this cutting edge technology project, which is a continuation of the work to date on additive layer manufacturing, and confirms its potential for industrial scale application. RAWFEED could dramatically transform the way high-value aerospace components are manufactured, as part of lean and efficient UK industry of the future.  We, and our partners, are very grateful for the support of the Technology Strategy Board, which is continuing to join us in investing in innovation in the UK aerospace industry.”

Delcam Ltd
Small Heath Business Park,
Birmingham, B10 0HJ, UK
www.delcam.com
Peter Dickin, Marketing Manager
Direct phone: 44 (0)121 683 1081
[email protected]

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Microfluidic devices with micron-scale resolutions

Micron-scale resolution – with today’s laser technology, resists for microcomponents can be produced cheaply and quickly. With a new compact laser system, individual trays are exposed directly.

Compact and powerful: The LPKF ProtoLaser LDI exposes resists with structures down to the micron range.
Compact and powerful: The LPKF ProtoLaser LDI exposes resists with structures down to the micron range.

LPKF, in cooperation with the Slovenian company Aresis and the University of Ljubljana, is developing new low-cost, fast processes for structuring of microcomponents. Maskless UV laser direct imaging (LDI) of photosensitive polymers (photoresists) offers numerous advantages over classic mask projection techniques.

Research and development in the field of microfluidic devices and micromechanical systems benefit from fast prototyping processes such as LPKF-LDI. Lab-on-a-chip devices help miniaturize processes and reduce liquid sample sizes as well as waste. This opens up tremendous possibilities for the LDI process in medicine, biology, chemistry, and physics. The applications are diverse – blood and cell analysis, medical diagnosis and screening, sensors (chemical, biological, environmental, and weapons technology; automotive engineering), synthesis of chemicals, and physical experiments.

Manufacturing microfluidic components
Three processes are mainly used to manufacture microfluidic devices on the scale of tens of nanometers to more than a hundred micrometers. The currently prevailing method of photolithography is primarily recommended for large-scale production. For frequent layout changes or low production quantities, though, the process is much too elaborate. In the electron beam method, the structures are written directly onto a resist. The electron beam has resolutions of between 20 and 50 nm. However, special resists, conductive substrates, a high vacuum, and an extraordinarily large amount of time are required for this process. With Laser Direct Imaging (LDI), a scanner-guided laser beam writes structures directly, rapidly, and precisely onto the photoresist without using a mask. This results in extremely smooth side wall edges.

LDI: fast, flexible, and precise
The LPKF ProtoLaser LDI can be used for production of microfluidic devices as well as MEMS, BioMEMS, integrated optics, and photonic experiments with microscale structures. In terms of precision, LDI surpasses all comparable systems for mask projection. Investment costs are considerably lower than for electron beam lithography and for numerous mask alignment systems. LDI even enables structuring of elements with web widths of less than a micron.
However, there are many more features: substrate exposure with a focused 375-nm TEM00 UV laser beam, which can also be used for standard UV resists; software-controllable laser focus (1 – 3 µm) for changing precision requirements; and an integrated camera for fine positioning of substrate and automated self-calibration as well as stitching mechanisms for real-time manufacturing of large samples.
The launch of the ProtoLaser LDI product will coincide with the presentation at MicroTAS in San Antonio, USA, from October 26 to October 30.

Various cylinders machined out of SU-8. Maximum precision at an extremely high aspect ratio.
Various cylinders machined out of SU-8. Maximum precision at an extremely high aspect ratio.

LPKF
Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
www.lpkf.de

Two spindles in a compact footprint

At the base of the specifications of the new s100 product line just unveiled by Bumotec, a simple idea: to create a product with maximum productivity in a minimal floor space. This while ensuring both quality of work and accuracy superior to the constraints of the watchmaking world. After 4 years of development, the s100mono and s100multi machines are being marketed and results exceed expectations. Meeting with Charles Dénervaud, responsible for marketing of the near-Fribourg based company.

Equipped with 2 electrospindles (max 60'000 rpm) and two systems to store tools, the s100mono maximises the use of hidden time.
Equipped with 2 electrospindles (max 60’000 rpm) and two systems to store tools, the s100mono maximises the use of hidden time.

Bumotec has developed a new concept of work with two spindles that is applied to several machines. The s100mono is a 3-linear-axis machining centre equipped with two working spindles. The s100multi machine has 4 workstations each with two spindles. In this case, the pallet holding the part moves from one position to another. The logic is the same as for a transfer machine. It is equipped with 144 tools, enabling significant gains on set-up times and unbeatable productivity. In this post, we will mainly talk about the s100mono version.

Lightning accelerations and maximised productivity
The machine is able to offer accelerations of more than 3 G (tested up to 5G). Our interlocutor says: “All the elements of the machine are known and proven. It offers a lot of possibilities and we discover new applications or methods enabling significant productivity gains every day”. And if nowadays the tools are not designed to work under those extreme conditions, it is evident that trends moves toward that direction and Bumotec is already prepared. To be able to control such a reactive machine, the company chose the Bosch Rexroth MTX Performance NC.

To benefit of hidden time to the maximum
In comparison with a classical single spindle machine, tests show very important cycle times improvements. When one requires 13 minutes with this technology, the s100 mono machine needs less than 8 minutes and an s100 multi only needs 2 minutes.

Comparison of cycle times between classical machining (one spindle) and the Bumotce S100mono and S100multi. In addition to high machine dynamics, it is mostly hidden time use which enables such gains. With two spindles, all tools changes or tools probing controls are conducted, while the second spindle is working.
Comparison of cycle times between classical machining (one spindle) and the Bumotec S100mono and S100multi. In addition to high machine dynamics, it is mostly hidden time use which enables such gains. With two spindles, all tools changes or tools probing controls are conducted while the second spindle is working.
In the case of realisation of larger series of parts or parts that require many operations, the s100multi combines four workstations identical to the s100mono version in a compact transfer centre.
In the case of realisation of larger series of parts or parts that require many operations, the s100multi combines four workstations identical to the s100mono version in a compact transfer centre.

Next opportunity to meet the specialists of Bumotec and to discover this new solution are Prodex (halle 1.0, stand B19) and Baselworld in early 2015 (Halle 4U, Stand E11).

Looking for a productive solution that does not require much space?

Bumotec SA
Route du Rontet 17
1625 Sâles
Suisse
T +41 26 351 00 00
F +41 26 351 00 99
[email protected]
www.bumotec.ch

We will go into deeper details of the new S100mono machine in our next issue.

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Energy efficiency needs to pay off

Keeping production energy requirements as low as possible is becoming an important competitive factor. The Institute of Production Management, Technology and Machine Tools, PTW for short, at the University of Darmstadt, will be represented with its own stand at the upcoming AMB.

Over 90,000 trade visitors and approximately 1,300 exhibitors are expected to attend AMB 2014 from 16 to 20 September 2014 and energy efficiency will be one of the important topic.
Over 90,000 trade visitors and approximately 1,300 exhibitors are expected to attend AMB 2014 from 16 to 20 September 2014 and energy efficiency will be one of the important topic. (Picture, the EvoDeco product range by Tornos includes intelligent technologies to save energy and to use it minimising waste.)

The most important issues facing production of tomorrow will be organised according to four clusters – one of which will focus on energy efficiency. Here, energy-optimised machine components and production machinery will be presented, as well as the research and demonstration project “eta-Fabrik”. In addition to the energy-related improvement of individual production facilities, their energetic networking, the machine periphery, utilities management and the factory building will also be considered. Prof. Dr.-Ing. Eberhard Abele, Executive Director of the PTW Institute, took a few moments to talk with us:

In your experience, what energy measures have the highest cost/benefit effect for manufacturers and customers?
Over the past few years, there have been a number of good solutions developed and implemented for energy-efficient machine tools. The measures are very diverse, ranging from constructive solutions such as the targeted optimisation of individual machine components, to new drive concepts, regenerative motors or the optimisation of processing. We must also bear in mind that a reduction of the cycle times is one of the most effective levers, as this often sees energy consumption linearly reduced. These measures that have been mentioned often involve additional costs for the customer. The key question is: are additional costs for energy-efficiency solutions economically feasible?

Efficiency involves more than just an economical machine tool. How can the production industry achieve a high degree of efficiency across the entire process?
The German industry is in direct international competition with a number of successfully producing countries such as China or South Korea. The competitive pressure on the international scene has increased dramatically the past few years. In my opinion, the challenge for the manufacturing industry will be adapting to new market conditions as flexibly and efficiently as possible. We need to learn to be faster than the competition in order to maintain our technological lead. This also calls for the communication of existing knowledge about known methods, such as lean system technology for example, in technical studies as early as possible. This is why, at PTW, we are working hard on the concept of learning factories – for students and employees of industrial concerns. Based on the success that we have had with this concept, there are currently further learning factories emerging in the area of Logistics and Energy Efficiency.
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www.messe-stuttgart.de/amb

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